Ultrasonic Systems Flaw Detector

Ultrasonic Systems Flaw Detector

FlexibleThe SFD-100 range of ultrasonic instrumentation can be moulded to your

inspection requirements, capable of producing A-scan, B-scan, C-scan

and strip chart information. It uses NDT Solutions’ bespoke powerful

data capture and high performance multi-channel pulser-receiver

hardware for mixed pulse-echo, through-transmission inspections.

The user interface can be designed by our systems integrators to

contain as much or as little information as your operators desire. Custom

workspace’s can be created in partnership with you to suit your workflow

requirements. Controls and displays can be grouped together on pages

of your design offering complete flexibility to meet the needs of a wide

variety of inspections.

If your intention is to use the instrument for several different inspections,

the SFD-100 software allows a workspace to be created for each

application, tailored to your needs.

Utilising InspectionWare, produced by Utex Scientific, our innovative

instrument can directly drive a wide range of motion control hardware

making it ideally suited for upgrading existing scanning equipment as

well as for commissioning new systems.

SFD-100 is available in two packages: a small compact lunchbox PC

that can easily be transported around site; and an industrial rack-mount

instrument for control and monitoring within a production plant. The

latter can be highly customised to suit existing control gear, sensors and

probes that you already own; the perfect solution for refits, upgrades,

and new installations.

1 A large palette of acquisition, inspec-

tion, data storage and DSP tools can

be added to your workspace to create

an interface that meets your inspection

requirements.

2 Pages and controls can be designed

to your specification, with the controls

that your operators need, and clear

results displayed in the format that you

want them. Report templates can be

generated showing only the data and

information you require in the layout

that you specify.

3 The end result is an interface

moulded to your specification, with the

functionality you need, presented in a

way that is efficient and clear for your

operators. We can even create a differ-

ent interface for the different products

you test.

Moulded to yourspecification

Data is digitised with amplitude resolution of 12 bits, sampled at rates of up

to 100MHz with over-sampling up to 400MHz available. Our multiplexed

systems are capable of operating at a PRF (Pulse Repetition Frequency)

of up to 100kHz. This extraordinary pulsing rate enables your parts to be

inspected using the SFD-100 at higher speeds and with greater resolution

whilst ensuring reliable defect detection at all times.

PowerfulThe SFD-100 instrument features 400V pulsers and sensitive receive

amplifiers with selective filters for the optimum defect detection. The

instrument is available with 1,2, 4, 8 or 16 channels.

Unlike many multiplexed ultrasound systems, the SFD-100 offers truly

independent configurations per cycle. All A-scan, TCG (Time Corrected

Gain) and gate parameters can be entirely separate for each cycle,

allowing for a wide range of different transducers and inspection types to

be performed simultaneously using the single instrument.

The SFD-100 has up to 6 measurement gates, with interface triggered TCG

having its own dedicated gate. Gates can be used for defect detection as

well as being used to make measurements from the A-scan data.

Powerful DSP (Digital Signal Processing) engines in the hardware and

software allow complex calculations, decision trees and hierarchies to be

constructed so that alarms, actuators, motors etc. can all be controlled

based on real-time inspection results.

The modular design of the hardware allows for additional channels and

functionality to be added, suited to your individual requirements.

SeamlessKey to the integration of any ultrasonic inspection instrument is the range

of interfaces available for connection with control and measurement

equipment such as PLCs, proximity sensors, encoders, temperature

sensors etc. The SFD-100 encompasses a range of digital and analogue

input/output ports, 6 simultaneous encoder inputs, high current switched

outputs and a 4-20mA current loop output.

The SFD-100 is more than just a measurement instrument; combining

ultrasonic testing with automation it can control your inspection facility.

With powerful motor control capabilities your scanning system can be

integral to your custom workspace.

For the standardised testing of parts, scans can be started with the press

of a button, inspection results viewed and printed, and report generation

can be automated. Documents and inspection results can be saved to

your network drives and printers. As you would expect, you can design

your reports specifically to your needs and include as little or as much

information as you require.

Your inspection software can be presented in all European and most

world languages.

FastOur dedicated data capture hardware ensures the very best scanning

performance, capable of the highest ultrasonic repetition rates. Data can

be captured in free running mode or synchronised to encoder position,

ensuring only the information you want is recorded.

All A-scan gating and rectification is performed digitally in dedicated

FPGA (Field Programmable Gate Array) hardware allowing fast multi-

channel C-scan and strip-chart capture.

Data is automatically selected to provide the operator with maximum

peak echoes (or minimum peak for back-wall) to ensure defects are never

missed due to the high speed repetition rates.

Data C

apturePro

cess

ing

Interfac

ing

Motion C

ontrol

General

Power Supply: Universal power supply (110-240V)

Dimensions: Lunchbox - 400 x 290 x 224mm (W x D x H)

Rack-mount processor unit - 482 x 510 x 177mm

Weight: Lunchbox - 12Kg

Rack-mount processor unit - 15kg

Application Software

A, B, C-scan and strip chart

A-scan envelope: Hilbert transform enveloping

Maximum peak A-scan displayed at very high pulser repetition rates

Customised user interface

Extensive DSP toolbox including FFT analysis

Waveform processors: Re-sampling, 2D and 3D data processors.

Evaluation tools: Polygon, Circle, Ellipse, Rectangle, Linear and Area measurements

with statistics.

Colour palette editing: Fully user definable colour maps

Motion control

Multi language support

Gating: Hardware and software gates for triggering alarms and/or recording

measurements

Filtering: Averaging and FIR filters

Noise glitch suppression: Electrical noise spikes from heavy machinery.

No. of cycles in acquisition sequence: 32

Modes of operation: pulse-echo and through transmission selectable per cycle

Sequenced Parameters: all gates and A-scan parameters per cycle

Electronic Specification

Receiver Inputs

Number of channels: 1, 2, 4, 8, 16

Switched input impedance: 50/100/ 200/500R per channel

Input attenuator: 0/-20/-40 dB

Input preamp: +20dB low noise preamp

Receiver gain: 90 dB

System Bandwidth: 0.1 to 25MHz (-6db)

Bandpass filters: 0.5/1/2.5/5/10/15MHz

TCG: No. of points: 16

Amplitude resolution: 0.3dB

Time resolution: 10ns

Total correction: 80dB

Slope range: 0 – 40dB/µs

Dynamic range: >80dB

Channel crosstalk isolation: >80dB

Same channel isolation: >80dB

Near surface resolution: 1.5mm for 1/64th FBH in steel.

Receiver noise: 1.3nV/Sqrt(Hz) to 2nV/Sqrt(Hz) depending on filtering

Connections: LEMO or BNC patch bays

Pulser Outputs

Output Voltage: -20V to -400V negative square wave

Rise and Fall times: 5ns ± 1ns

Pulse width: 10ns to 2us in 10ns steps

Output protection: Fully short circuit output protected

Max Repetition rate:

@10ns PW - 100KHz / number of cycles used

@50ns PW - 20KHz / number of cycles used

Hardware Processing

Gates: 6 gates + 1 interface gate

Gate modes: C-scan / Strip Chart

Peaks per gate: 1st, 2nd, …10th, maximum, last

Gate triggering: peak, leading/trailing flank, zero crossing

Measurement types: Relative or absolute in any combination

Rectification: RF, FW, HWP, HWN

Over sampling: up to 400MHz

DAC gates: Available on request

Backwall Attenuator gates: Available on request

Automation

Motor control: servo or stepper up to 6 axis

Encoders: 6 channel single ended/differential

Input / Output

External Trigger Input: 3.3V pulse input (5V tolerant)

Sync output: 3.3V pulse output

High current switches: 4 Channels, 500mA, 30V max rating.

PC Interfaces: USB, RS232, Parallel, SVGA, PS2

Option 1: SAP, T-SYNC: TTL compatible outputs

High current digital outputs: 16 outputs for connection to TTL/PLC etc.

Analogue outputs: 16 outputs (0-5V range)

Option 2: Analogue Inputs: 8 Channels (± 2.5V Range)

Analogue Outputs: 8 Channels (0-5V Range)

Current loop output: 4 to 20mA output

Digital I/O: 12 lines of Bi-Directional 3.3V (5V tolerant)

ToughAll of NDT Solution’s products are designed with the highest quality

electronics, and the SFD-100 is no exception.

Designed to fit standard industrial rack systems, your SFD-100 can be

commissioned with power filtering, protection and with battery backup

for brown-outs or power cuts. Air conditioning and filtration units can

be fitted to rack enclosures for operation in extreme climates or dusty

environments.

Our novel noise filtering algorithms protect the instrument from

electrical machine noise, preventing false gate triggers. Coupled with

our maximum echo algorithm, we ensure excellent defect detection

and the best possible rejection of unwanted noise.

The SFD-100 encoder inputs are all auto-sensing differential as

standard, providing the best quality position data.

The SFD-100 instrument is the complete, robust instrument, designed

to meet the most demanding of testing requirements.

Application Areas

Rail Manufacture Quality Control

C-Scan Inspection

Forging Quality Control

Billet Quality Control

Bar/Tube Quality Control

Weld Quality Control

Casting Quality Control

Multi-Channel Thickness Mapping

Ultrasonic ProbesNDT Solutions offer an extensive range of transducers tailored to the individual requirements of your ap-

plication. From standard to ultra-high resolution, bespoke probes we can provide you with the ideal solution

to meet the inspection demands. Transducers can be manufactured in a number of styles including immer-

sion, contact or for use within scanning bubblers. All transducers are manufactured to exacting standards

for acoustic, electronic and mechanical properties, supplied with complete test certification.

© Copyright NDTS 2006. All rights reserved.

Tel +44 (0) 1246 267550

Fax +44 (0) 1246 269381

E-mail sales@ndtsolutions.com

Web www.ndtsolutions.com

NDT Solutions Ltd

Dunston Innovation Centre

Dunston Road

Chesterfield, UK

S41 8NG

ExampleThe schematic shown above illustrates a typical pipe testing

system. Existing plant electronics control the testing line, which is

equipped with position encoders and proximity sensors to monitor

the position of the product being tested.

NDT Solutions provide an additional cabinet, housing everything

required to perform the ultrasonic inspection, including a large

display, industrial alarm system, power protection, printer, and of

course the SFD instrument itself.

1

2

3

4

5

1 Rack Enclosure for SFD instrument, alarms, display and printer

2 Ultrasonic probes

3 Distance encoders, proximity sensors etc.

4 Existing industrial plant controller

5 Interfacing between plant controller and SFD instrument

The Portable SFDL-100

The SFDL-100 is a portable instrument offering a multi-channel systems’

flaw detector in a lightweight package. The SFDL-100 uses the same

high quality ultrasonic and data capture electronics as the SFD-100

with up to 8 fully independent channels. Choose from a range of pre-

configured workspaces for common applications, or we can design

a custom workspace for your requirements. The SFDL-100 can also

interface to a wide range of hardware, offering digital and analogue

inputs and outputs.

Ultrasonic Systems Flaw Detector

A-Scan DisplayThe SFD-100 displays a large A-Scan for any selected

cycle in the inspection. The parameters you wish to include

can be displayed in most world languages providing a clear

interface for your operators. We can also provide controls

to set up your scan with encoder position readouts, with

operator details, part information and any other information

you need to include in your evaluation.

Multi A-Scan DisplayFor multiple channel applications, the ability to see and compare A-Scans from several cycles in the inspection

is important. In this example six A-Scans are shown however for more complex inspections a larger number

may be included. As can be seen, each A-Scan has its own gain control on this particular set up. It is your

choice which controls and information are displayed on each page, configured to suit your needs.

Alarms and GatesThe SFD-100 has a powerful set of gates which may be applied completely independently on each cycle.

A-Scan gates operate in dedicated FPGA hardware for optimum performance, and software gates are also

available that can be applied to A-Scan and strip chart plots. Gates can be used to drive analogue outputs

and trigger alarms which are clearly displayed in software to your specification, and may connect to external

alarm units as required. Alarms and analogue outputs can be set from calculations of any gate output in any

cycle of the inspection, allowing complex decision making functionality.

Strip Chart DisplaysStrip charts showing the measurements from several cycles can be displayed live during the inspection,

containing amplitude, time of flight data, or a mixture of each. As many strip charts can be included as

your inspection demands and additional gates can be created on the strip chart itself for triggering alarms

and to control plant mechanics. The SFD-100 is not limited to strip charts, it can produce C-Scan and

B-Scan displays too with powerful evaluation tools and colour map controls.

The SFD-100 is the complete, versatile, multiple channel ultrasonic instrument. The electronic hardware can

be specified to meet your inspection requirements incorporating displays, alarms and interfacing to your

scanning equipment. For automated inspections, the instrument is supplied as a robust 19” rack with air

filtering and temperature control as necessary. The performance of the ultrasonic hardware is delivered to

the user through a customised workspace to provide the exact interface that you want. The examples below

show just a small selection of what is possible with the SFD-100. For automated applications, reports can

be automatically generated, and batch reports may be created and printed summarizing the key information

you need for your inspection.

© Copyright NDTS 2006. All rights reserved.

E-mail sales@ndtsolutions.com

Web www.ndtsolutions.com

NDT Solutions Ltd, Dunston Innovation Centre, Dunston Road, Chesterfield, UK, S41 8NG

Tel +44 (0) 1246 267550

Fax +44 (0) 1246 269381